SC-21-13 – Anti-spray Front Fender Retrofit – 2020-2021 Proterra 40′ ZX5

February 1, 2021 NHTSA CAMPAIGN NUMBER: 21V040000

Front Fender Flare Improvement

Driver visibility may become impeded, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V040

Manufacturer Proterra, Inc.

Components STRUCTURE

Potential Number of Units Affected 21

 

Summary

Proterra, Inc. (Proterra) is recalling certain 2020-2021 40′ ZX5 vehicles. These vehicles have a front fender flare which may cause mud, dirt, debris, rain and snow to splash onto the driver’s side window and mirror.

 

Remedy

Proterra will notify owners, and dealers will install a retrofit fender flare, free of charge. The recall began February 9, 2021. Owners may contact Proterra customer service 1-864-438-0000. Proterra’s number for this recall is SC-21-13.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

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RECALL

ISSUE DATE:	1-27-2021
SERVICE BULLETIN SUBJECT:	Anti-spray Front Fender Retrofit
VINs or MODELS AFFECTED:	Service Specified Buses
COMPLETE BY:	Next Service Opportunity
SERVICE BULLETIN #:	SC-21-13
Labor Operation Code:	N/A

 

 

NOTICE! It is expected that this process will require 2 hours per bus. Please schedule appropriately to minimize vehicle downtime.

 

ANTI-SPRAY FRONT FENDER RETROFIT

Retrofit Description:

This procedure adds wider fender flares to prevent slush, water, and mud spray from splashing onto the driver’s window and mirrors,

 

Tools/Parts Required

Tools and Supplies Required:

• Power Drill
• 1/4-Inch Drill Bit
• 21/32-Inch Counterbore
• 36-Grit Sanding Disk
• Ratchet
• 5mm Allen Socket
• T-25 Torx Socket
• T-30 Torx Socket
• Calibrated Torque Wrench
• Orange Torque Stripe Paint
• Protective Gloves
• Tongue Depressors
• Shop Towels
• Isopropyl Alcohol

 

 

 

Kit Parts Required:

056528	Service Kit – Extra Wide Fender Flare (Consisting of)
128-2517	FLARE, FENDER, 5.5″EXTRUSION, FRONT	18 FT
006430-001	TAPE, 3M VHB, DOUBLE SIDED, 1 X .09″ THICK 43 FT	1 EA
019493-005	SCREW,BUTTON,FLG,TORX,BLACK, M6-1.0X25X25	6 EA
128-8722	BAR, ATTACHMENT, FENDER, 5.5″	3 EA
129-0295	BAR, ATTACHMENT, FENDER, 5.5″, SS, FRONT	1 EA
046986	WITTEN, 150-M6X1.0-14-SS	6 EA
050104	WASHER FLAT, M6 X 25 X 1.8	16 EA
129-0296	SPACER, FENDER, ATTACHMENT, BOTTOM	2 EA
113-3470	SCREW BUTTON FLANGE, TORX, M5-0.8X30X30	16 EA
016877	WSHR, DIN 125A, SST, M8	6 EA

 

Parts required but Not included in the Kit:

009479	RESIN, EPOXY, WEST SYSTEMS	1 EA
027017	FILLER, HIGH DENSITY, WEST SYSTEMS	1 EA
009499	HARDENER, EPOXY, FAST, WEST SYSTEMS	1 EA
043223	EQUIPMENT, SERVICE, WEST SYSTEM MINI PUMP	1 EA

 

Procedure:

1. Complete the Proterra approved Lockout/Tagout procedure to make the bus safe for work.

 

2. Use hand tools only for installing fasteners in this procedure. Power tools are likely to cause the inserts to de-bond and spin.

 

3. Using a Ratchet with a T-25 Torx Socket, remove both front Fender Flares from the front of the bus and set them aside.

 

4. Working inside the Streetside Wheel Well, locate the lower front Insert that was used for mounting the original Fender Flares.

 

5. Using a Power Drill with a 1/4-Inch Drill Bit, drill out the lower front insert.

 

6. Using a Power Drill with a 9/16-Inch Counterbore, enlarge the hole to install a Witten (046986).

 

7. Using a Power Drill with a 1/4-Inch Drill Bit, drill a pilot hole parallel with the previous hole but 40mm closer to the inside of the bus.

 

8. Using a Power Drill with a 9/16-Inch Counterbore, enlarge the hole to install a Witten (046986).

 

9. Working inside the Curbside Wheel Well, locate the lower front Insert that was used for mounting the original Fender Flares.

 

10. Using a Power Drill with a 1/4-Inch Drill Bit, drill out the lower front insert.

 

11. Using a Power Drill with a 9/16-Inch Counterbore, enlarge the hole to install a Witten (046986).

 

12. Using a Power Drill with a 1/4-Inch Drill Bit, drill a pilot hole parallel with the previous hole but 95mm closer to the inside of the bus.

 

13. Using a Power Drill with a 1/4-Inch Drill Bit, drill out the lower rear insert that was used to secure the original Fender Flare on both the Curbside and Streetside of the front wheel wells.

 

14. Using a Power Drill with a 9/16-Inch Counterbore, enlarge the holes to install Wittens (046986).

           

15. Mix West Systems 105 Epoxy Resin with West Systems 205 Hardener to get the amount required to install the six Inserts (046986).

 

16. Mix in West Systems 404 High Density Filler until the mixture has the consistency of peanut butter.

 

17. Using a plastic bag with a corner cut off or a tongue depressor, apply the Epoxy to the outer surfaces of the Inserts (046986).

 

18. Place the Epoxy covered Inserts (046986) into the mounting holes. Make sure that the Inserts are square with the body and that the tops of the Inserts are just below the top surface of the body. Use the small Plastic Keepers that are supplied with the Inserts to keep them square to the floor.

 

19. Allow at least three hours for the Epoxy to cure.

 

20. Using Shop Towels and Isopropyl Alcohol, clean the Fender Flares that were removed from the bus.

 

21. Apply 3M VHB Tape (006430) to the Extruded Fender Flare (128-2517) as shown in the following photograph.

 

22. Mate the one of the original Fender Flares on top of the Extruded Fender Flare (128-2517). Ensure that the original Fender Flare is placed against the molded lip on the Extruded Fender Flare.

 

23. Using an Approved Safety Knife, trim the Extruded Fender Flare (128-2517) to match the length of the original Fender flare.

 

24. Repeat this process to mate and trim the Extruded Fender Flare (128-2517) to the remaining original Fender Flare.

 

25. Using the slots in the original Fender Flares as a template, mark the holes in the original Fender flares for drilling using a White or Silver Permanent Marker.

 

26. Using a Power Drill with an 8mm Drill Bit, drill holes in the marked locations on the Extruded Fender Flares (128-2517).

 

27. Using a Ratchet with a T-30 Torx Driver, install the combined Fender Flares using M5 Screws (113-3470) and Washers (050104). Begin the process using the top two locations on the Fender Flares. After the two top fasteners are installed, alternate sides of the Fender Flares while installing the fasteners toward the bottom of the Fender Flares. The installation order is shown by the numbers in the first photograph.

 

28. Repeat the process to install the combined Fender Flare onto the other side of the bus.

 

29. Working at the rear of the Wheel Well, install the Bar Attachment (128-8722) as shown in the following photograph. The Bar Attachment should be between to Mud Flap and the original bracket. Use the original fasteners to attach the Mud Flap ensuring that the screws pass through the slot in the Bar Attachment. Use a M6 Screw (018081-005) and Washer (016877) to attach the Bar Attachment to the newly installed Witten (046986).

 

30. Repeat the process to install the Bar Attachment (128-8722) on the other side of the bus.

 

31. Working on the Curbside of the bus, install a Spacer (129-0296) as shown in the following photograph. Secure the Spacer and Fender Flare to the bus using M6 Screws (018081-005) and Washers (016877) and the newly installed Wittens (046986).

 

32. Working on the Streetside of the bus, install a Spacer (129-0296) as shown in the following photograph. Secure the Spacer and Fender Flare to the bus using M6 Screws (018081-005) and Washers (016877) and the newly installed Wittens (046986).

 

33. Remove the Lockout/Tagout Devices and return the bus to service.

 

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IMPORTANT SAFETY RECALL

NHTSA Recall Number: 21V-040

This notice applies to your vehicle: (Insert VIN or VINs)

 

Month Day, 2021

Dear Proterra Transit Bus Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

What is the reason for this notice?

Proterra has decided that the current design of the front fenders flare may contribute to splashing of dirt/mud/debris/snow/rain onto the driver’s side window and side mirror impeding visibility while driving. The driver’s visibility may become impeded, increasing the risk of a crash. The affected urban transit buses are certain 2020 – 2021 MY 40’ ZX5.

 

Why is your vehicle being recalled? 

A retrofit kit is available. Proterra will provide a repair of the retrofit kit at no cost to you.  We apologize for the inconvenience. We are committed to your safety, the safety of your customers, and your continued satisfaction with our products, and we request that you remedy your bus(es) promptly.

 

IMPORTANT

• Your Proterra vehicles are subject to NHTSA Safety Recall No. 21V-040 because a new design front fenders flare retrofit kit is now available.
• Proterra will remedy the issue. Service instructions are provided in technical service bulletin SC-21-13.
• This remedy will be provided free of charge.
• Contact Proterra’s customer service department at 864- 438-0000 or ServiceParts@Proterra.com if you have any questions.

 

What will Proterra Do?

Proterra will provide the retrofit kit to you at no charge.  Service repair instructions are provided in service bulletin SC-21-13.  Proterra customers should submit a warranty claim for the labor associated with the repair, which is estimated to be approximately two (2) hours.

 

What Should You Do?

You should contact your Regional Service Manager or Field Service Representative  to ensure that the necessary service retrofit kit repair is made as soon as possible.

 

What If You Have Already Repaired the Defect?

If you have previously paid for a repair that addresses the defect described in this letter, you still need to have this recall performed by Proterra ensure the correct parts were used.  However, you may be eligible for a reimbursement of the previous repair.  Please contact Proterra’s customer service team at 864-438-0000 or ServiceParts@Proterra.com to verify eligibility and process your reimbursement request.

 

What If You Have Other Questions? 

Please contact Proterra’s customer service department at 864- 438-0000 or

ServiceParts@Proterra.com with any questions or concerns about this information. If, after contacting Proterra’s customer service department, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 20V-664.

 

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

Sincerely,

 

William Pack
Vice President, Quality
Proterra Inc.

 

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2 Affected Products

Vehicle

MAKE	MODEL	YEAR
PROTERRA	ZX5	2020-2021

 

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9 Associated Documents

Defect Notice 573 Report

RCLRPT-21V040-5429.PDF 213.629KB

 

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Recall Acknowledgement

RCAK-21V040-3278.pdf 645.499KB

 

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Remedy Instructions and TSB

RCRIT-21V040-9993.pdf 2099.049KB

 

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Owner Notification Letter(Part 577)

RCONL-21V040-4122.pdf 118.12KB

 

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Recall Quarterly Report #1, 2021-1

RCLQRT-21V040-9254.PDF 211.22KB

 

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Recall Quarterly Report #2, 2021-2

RCLQRT-21V040-3548.PDF 211.22KB

 

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Recall Quarterly Report #2, 2021-2

RCLQRT-21V040-8258.PDF 211.224KB

 

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Recall Quarterly Report #3, 2021-3

RCLQRT-21V040-1394.PDF 211.309KB

 

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Recall Quarterly Report #4, 2021-4

RCLQRT-21V040-5611.PDF 211.419KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V040&docType=RCL

 

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